Method and Device for Aseptic Filling

ABSTRACT

A method and a device for the aseptic filling of a liquid food product that contains at least one solid particle, including disinfection with a disinfection unit of at least a part of the external surface of at least one first container which contains the solid particle, and disinfection of at least a second container, opening of the disinfected first container with an opening unit and removal of the solid particle, and filling via a filling unit of a disinfected second container with the solid particle and a liquid food.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of priority of German Application No. 102010062797.6, filed Dec. 10, 2010. The entire text of the priority application is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The disclosure relates to a method and device for the aseptic filling of liquid food products which contain solid particles.

BACKGROUND

There is a growing market for liquid food products such as fruit juice drinks containing solid particles such as, for example, whole pieces of fruit, especially aloe vera, coconut, pineapple, peach or mandarin orange sacs. These pieces of fruit are added to the carrier juice in proportions of up to 50 percent by weight and can measure up to 1 cm×1 cm×1 cm.

In traditional filling plants, food products of this type are filled into containers such as glass bottles, PET or polyolefin bottles or pouches, and the carrier fruit juice and the fruit pieces are filled into the container separately. The fruit pieces are normally delivered to the filling plants in pasteurized and autoclaved containers, mainly tin cans in 5 to 10 kg pack sizes. The containers are opened shortly before filling, emptied and if necessary suspended in a carrier liquid before the filling process. The pasteurized fruit piece suspension is then taken to a predosing system and then filled together with a second stream of fruit juice, which may have been subjected to a separate thermal treatment.

When the autoclaved containers are opened to remove the fruit pieces, recontamination with all sorts of microorganisms occurs, so that the fruit pieces, or the suspension of fruit pieces in the carrier liquid, have to be pasteurized again. Pasteurisation is normally carried out through thermal treatment in a flash pasteuriser. In addition to the thermal stress, the fruit pieces are subjected to a high level of mechanical stress, from the effect of pumps, control valves, etc., by the repeated pasteurisation stage required. This thermal and mechanical stress leads in turn to unwanted product damage, such as the reduction in the size of the particles and a more widespread particle size distribution of the solid particles. Furthermore, the traditional methods and devices are very cost-intensive and inefficient because of this additional pasteurisation stage.

BRIEF SUMMARY OF THE DISCLOSURE

One aspect of the present disclosure is the provision of a cost-effective, efficient method and a device for the aseptic filling of liquid food products containing solid particles in which the solid particles are subjected to the lowest possible thermal and mechanical stress, thus ensuring a high quality of the food product.

The method according to the disclosure for the aseptic filling of a liquid food product that contains at least one solid particle covers the following steps:

-   -   Disinfecting at least one part of the external surface of at         least one first container that contains the solid particle, and         disinfecting at least one second container,     -   Opening the disinfected first container and removing the solid         particle,     -   Filling a disinfected second container with the solid particle         and a liquid food.

The term “disinfecting” is understood to mean the treatment of the container with suitable disinfectants, such as peracetic acid, hydrogen peroxide or hot water vapor, whereby microorganisms occurring on the container surface are reduced at least by the factor log 3, preferably log 5, and particularly preferably log 7, i.e. by the factor 1,000, 100,000 or 10,000,000. Suitable disinfecting methods are known in the state of the art and are not explained further here.

The term “first container” refers to the container in which the solid particles are delivered. The term “second container” refers to the container in which the liquid food product is filled. The external surface of the first container is completely disinfected, or at least a part is disinfected. In the case of the empty second container, both the external surface and the internal surface of the container are completely disinfected.

Because of the previous disinfection of the first container before the opening and removal of the solid particles, there is no need for another pasteurization of the solid particles, since the opening and removal of the solid particles from the first container are carried out aseptically and thus recontamination with microorganisms is impossible. As a result, the thermal and mechanical stress on the solid particles can be minimized, which means that the size and particle size distribution of the solid particles are not negatively influenced, which results in a high quality of the food product. At the same time, the method is cost-effective and efficient because of the absence of the repeated pasteurization stage of the solid particles.

In particular, it is preferred, as regards the method, that the external surface of the first container which contains the solid particle is completely disinfected, and the disinfected container is transferred to a clean room before the opening step. The opening of the first containers and the removal of the solid particles from the first container within a clean room ensures particularly effectively that the opening and emptying process is carried out aseptically and hygienically so that recontamination of the solid particles is impossible. The filling step can be carried out inside or outside the clean room.

In an alternative embodiment of the method, the first container is only partly disinfected and then a disinfected part of this first container is docked on to an opening unit and opened. In this embodiment, the step of docking the disinfected part of the first container to the opening unit guarantees that the removal of the solid particle from the first container is carried out under aseptic conditions. The advantage of this embodiment is that the process does not have to take place within a clean room, i.e. that no clean room is necessary and only a part of the first container which contains the solid particle has to be disinfected. In this way, a particularly cost-effective version of the method is possible. The case is particularly preferred in which the solid particles are delivered in a cylindrical can and only the base and/or the cover of the can is disinfected and opened.

In a further preferred embodiment, the method also includes, between the opening step and the filling step, the step of producing a mixture (i.e. a suspension) of the solid particle with a liquid carrier, and/or the step of predosing the solid particle and/or the mixture of the solid particle with a liquid carrier. The liquid food, i.e. the fruit juice in particular, may be used as the liquid carrier, for example. According to the disclosure, however, the use of other carrier liquids is comprised. The suspension of the solid particles, especially if the solid particles are present in the first containers as pure solids, makes handling of the solid particles during the filling process easier. However, it is also possible that the solid particles in the first container are already present as a suspension, i.e. as a mixture with a carrier liquid, so that there is no need for the step of making the mixture. The step of predosing the solid particle and/or the mixture of the solid particle with the liquid carrier simplifies filling into the second container, thus allowing a particularly effective management of the procedure.

In this, it is particularly preferred that the solid particles, after removal from the first container, run consecutively through an opening unit, a dilution unit and a predosing unit in a vertical direction from top to bottom. A process management of this type further minimizes the mechanical stress on the solid particles. As a particular preference, the downward movement of the solid particles takes place through gravity so that there is no need for conveyance using pumps or similar, which additionally reduces the mechanical stress on the solid particles.

In particular, the opening step comprises perforating the first container with a perforator, whereby as a particular preference the perforator perforates the container in a vertical direction from top to bottom. Preferably the perforator can in this way make two openings in the first container, i.e. an outlet opening and an equalizing opening. The opening made by the perforator must be large enough for the solid particles to come out of the opening of the container and for the container to empty completely as quickly as possible. As a particular preference, the perforator makes a funnel shape in the outlet opening so that the container does not need to be turned.

Furthermore, the method preferably comprises the step of testing the leak-tightness of the first container that contains the solid particles. The leak-tightness is determined in particular through a pressure test, whereby the containers are placed under pressure (negative or positive) by means of a device and tested for pressure stability. Alternatively, the leak-tightness test can be carried out using an ultrasonic measurement in which the containers are hit with ultrasonic waves which are generated with an ultrasonic wave device. If the containers are leaky, the product emerges, and this can be detected using a sensor. Leaky and insufficiently autoclaved containers can thus be sorted out of the process and the process can be carried out effectively and the high quality of the resulting food product maintained.

Alternatively or in combination with it, the method comprises in a further preferred embodiment the step of detecting metal with a metal detector in a second container filled with the liquid food product. In this way, the presence of metal residues which could occur, for example, when the first containers are opened can be detected and containers contaminated in this way can be removed. This further increases the effectiveness of the method and the quality of the resultant food product.

In particular, it is preferred that the method comprises the step of pasteurizing the liquid food and/or the liquid carrier with a pasteurizing unit. In this way, it is guaranteed that the resultant food product meets the hygienic requirements. The pasteurization step in the method according to the disclosure is preferably carried out in such a way that the solid particles are not treated. Such an embodiment of the method can ensure aseptic filling and thus guarantee a high level of hygienic purity of the food product without the solid particles being too mechanically and/or thermally stressed. Pasteurization methods and systems are known in the state of the art and are not explained further here.

As a preference, the method includes the step of introducing the first container which contains the solid particle and/or the empty second container into the clean room via at least one transfer device and/or the method comprises the step of removing the empty first container and/or the second container filled with the liquid food product from the clean room via at least one second transfer device. The entry/removal of the containers out of the clean room guarantees aseptic filling and thus a high level of hygiene of the food product.

The device according to the disclosure for the aseptic filling of a liquid food product that contains at least one solid particle comprises:

-   -   at least one disinfection unit to disinfect at least one part of         the external surface of at least one first container that         contains the solid particle and to disinfect at least one second         container,     -   at least one opening unit to open the disinfected first         container and to remove the solid particle,     -   at least one filling unit for filling a disinfected second         container with a liquid food and the solid particle.

The presence of the disinfection unit for the disinfection of at least one part of the external surface of the first container ensures that the liquid food product is filled aseptically, whereby it is also possible at the same time to do without another pasteurization of the solid particle, so that the thermal and mechanical stress on the solid particles is minimized. In this way, a high quality of the liquid food product as regards the hygienic requirements and the size and size distribution of the solid particles can be guaranteed. Furthermore, the device can be operated effectively and economically since the device does not include any additional device for pasteurization of the solid particles after removal from the first container.

The term “filling unit” comprises according to the disclosure the following embodiments: (a) a filler; (b) a blender and a filler; (c) two fillers (i.e. a predosing unit and a filler); (d) a double-aseptic filler valve which mixes two or more components in the valve. Corresponding embodiments are known in the state of the art and are not explained further here.

Preferably, the device includes additionally a clean room in which the opening unit is located and in which a completely disinfected first container is opened. This layout within a clean room particularly effectively ensures the aseptic opening and filling of the first container, so that recontamination of the solid particles is excluded. The filling unit can be inside or outside the clean room.

As an alternative, the device may preferably include a docking unit which is located at the opening unit, and particularly preferably directly above the opening unit. A disinfected part of the container is docked before opening onto the docking unit in such a way that when the first container is opened, the solid particles are transferred directly and without recontamination into the opening unit. In this way, the device is particularly efficient and cost-effective. In this embodiment of the device, the docking unit guarantees that the solid particle is removed from the first container under aseptic conditions. The advantage of this embodiment is that the device does not need to comprise a clean room and only a part of the first container which contains the solid particle has to be disinfected, which means that the device can be made particularly cost-effectively.

In particular, it is preferred that the device also includes a dilution unit for making a mixture of the solid particle with a liquid carrier. This dilution or suspension of the solid particles with the liquid carrier makes the handling of the solid particle within the device easier.

Alternatively or in combination with this, the device also includes a predosing unit for predosing the solid particle and/or the mixture of the solid particle with the liquid carrier. This predosing unit allows predosed portions of the solid particle to be generated, which can be transferred particularly effectively to the second container.

It is particularly preferred that the opening unit, the dilution unit and the predosing unit are laid out in a vertical direction from top to bottom. With this layout, after the solid particles have been removed, they can run through the opening unit, the dilution unit and the predosing unit with the lowest possible mechanical stress on the solid particles, which further improves the quality of the food product.

As a particular preference, the opening unit comprises a perforator which, as a particular preference, is laid out in relation to the first container in such a way that the perforator can perforate the first container in a vertical direction from top to bottom. The shape of the perforator should preferably be such that easy cleaning is possible, i.e. it should not have any undercuts or similar. Furthermore, the shape of the perforator should preferably have the smallest possible displacement volume in order to minimize the mechanical stress on the solid particles in the container. Preferably, on the lower surface of the container, a funnel is produced from which the solid particles can emerge without any further mechanical stress, from pumps etc., being necessary.

Furthermore, the device preferably comprises a test unit to check the leak-tightness of the first container that contains the solid particle. As an alternative to this or in combination with it, the device can include a metal detector for detecting metal in a second container filled with liquid food. Leaky and/or insufficiently autoclaved containers can thus be sorted out of the process and the device can thus be operated effectively with the high quality of the resulting food product being ensured.

It is particularly preferred that the device has at least one pasteurizing unit for pasteurizing the liquid food and/or the liquid carrier, with the pasteurization unit preferably being laid out in such a way that the solid particles are not treated. In this way, the quality of the resulting food product can be further increased, since this guarantees aseptic filling and thus a high level of hygienic purity of the food product without the solid particles being overstressed mechanically and/or thermally.

Preferably, the device can comprise at least a first transfer device for introducing the first container that contains the solid particle and/or an empty second container into the clean room. Alternatively or in combination with it, the device can comprise at least a second transfer device for introducing an empty first container and/or a second container filled with the liquid food product out of the clean room. The transfer devices guarantee aseptic filling and thus a high level of hygiene of the food product, which makes a particularly effective device design possible.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure and its advantages are further explained on the basis of the embodiments shown in the following drawings. These show the following:

FIG. 1: a schematic sectional drawing of an embodiment of a device according to the disclosure with clean room;

FIG. 2: a schematic sectional drawing of a further preferred embodiment of a device according to the disclosure with clean room;

FIG. 3: a schematic sectional drawing of an alternative embodiment of a device according to the disclosure with docking device;

FIG. 4: a part of a device according to the disclosure with a combined opening unit, dilution unit and predosing unit;

FIG. 5: a schematic embodiment of a perforator to open a first container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows a device with a testing unit 40 for testing the leak-tightness of a first container 6, plus a disinfection unit 20 for disinfecting the external surface of the first container 6. Furthermore, the device comprises a clean room 22 with transfer device 46 for the introduction of full first containers 6 and a second transfer device 48 for the removal of empty first containers 10. The clean room 22 comprises an opening unit 24 for opening the disinfected first containers 16, and for removing the solid particles 4 out of the containers 16. Furthermore, the device comprises a second disinfection unit 20 for disinfecting the empty second containers 8 into which the food product 2 is filled, and a filling unit 26. This is linked via pipes with the opening unit 24 and a pasteurization unit 44, through which the solid particles 4 or the liquid food 18 are taken to the filling unit 26. In addition, the device comprises a metal detector 42 for the detecting of metal in a second container 12 filled with the liquid food product 2.

In the device according to FIG. 1, a method according to the present disclosure can be carried out as follows:

After delivery, first containers 6, which contain solid particles 4, are tested initially for leak-tightness in the testing unit 40. Leaky containers 50 are sorted out of the testing unit 40. After the leak-tightness test, the leak-tight first containers 6 are disinfected in the first disinfection unit 20, whereby here the entire external surface of the containers 6 is treated. After disinfection, the disinfected first containers 16 are transferred via the first transfer device 46 into the clean room 22, and opened by means of the opening unit 24 located there. After opening and after removal of the solid particles 4 the empty containers 10 are removed from the clean room 22 via the second transfer device 48. In parallel with this, in the second disinfection unit 20, empty second containers 8 are disinfected and transferred to the filling unit 26, and liquid food 18 is pasteurized using the pasteurization unit 44. After this, the removed solid particles 4 from the opening unit 24 and the liquid food 18 from the pasteurization unit 44 are transferred via pipes to the filling unit 26 and filled there into the sterilized second container 14. The second containers 12 filled in this way with the food product 2 are then tested with the metal detector 42 for the presence of metal and any contaminated containers 50 are removed.

A further embodiment of the device is described in FIG. 2. This is constructed in a similar way to the device according to FIG. 1, with the difference that in this embodiment the filling unit 26 is in the clean room 22. In addition, this embodiment includes two first transfer devices 46 and two second transfer devices 48 for the introduction/removal of the first containers and the second containers from the clean room 22.

In the device according to FIG. 2, a method according to the present disclosure can be carried out in a way similar to that described above. The only difference in the embodiment according to FIG. 2 is that the step of filling takes place in the clean room 22, whereby the empty second containers 8 are introduced into the clean room 22 and the filled second containers 12 are removed from the clean room 22.

An alternative embodiment of a device is shown in FIG. 3. This device comprises a testing unit 40 for checking the leak-tightness of a first container 6 which contains the solid particle 4 and a disinfection unit 20 for disinfecting a part of the external surface of a first container 6. A docking unit 28 is positioned directly at the disinfection unit 20, which docking unit is connected in turn directly with the opening unit 24. Furthermore, the device includes a filling unit 26 and a second disinfection unit 22 directly connected with it for disinfecting the empty second containers 8. The filling unit 26 is connected by pipes with the opening unit 24 and a pasteurization unit 44 through which solid particles 4 and/or pasteurized liquid food 18 can enter the filling unit 26. Furthermore the device comprises a metal detector 42 to detect metal in a second container 12 filled with liquid food product 2.

In the device according to FIG. 3, a method according to the disclosure can be carried out as follows:

After the delivery of autoclaved first containers 6 which contain solid particles 4, these are tested for leak-tightness in the testing unit 40 and if necessary removed from the process 50. After the leak-tightness test, the containers 6 are disinfected in the first disinfection unit 20, whereby the containers are only disinfected partly, here only on the lower surface 17. After this, the partly disinfected first containers 15 are transferred to the docking unit 28. In the docking unit 28, the disinfected part 17 of the first container 15 is opened in such a way that the disinfected part 17 is directly above the opening unit 24, so that non-disinfected parts of the first container do not come into contact with the solid particles 4 or with the opening unit 24. After the opening of the first containers 15 and the removal of the solid particles 4, the empty first containers 10 are removed from the docking unit 28. In parallel with this, empty second containers 8 are disinfected in the second disinfection unit 20 and then taken to the filling unit 26. Furthermore, the pasteurization of the liquid food 18 is carried out. The removed solid particles 4 and the liquid food 18 are then taken via a pipe to the filling unit 26. In the filling unit 26, the disinfected second container 14 is filled with the solid particle 4 and the liquid food 18. After emerging from the filling unit 26, the second container 12 filled with the liquid food product 2 is tested for metal using the metal detector 24 and any contaminated containers 50 are removed.

FIG. 4 shows a preferred embodiment of a part of a device according to the disclosure which contains a combined opening unit 24, dilution unit 30 and predosing unit 36. The opening unit 24, the dilution unit and the predosing unit 36 are laid out in a vertical direction from top to bottom in such a way that after the emptying of the first containers 15/16 the solid particles 4 are moved from top to bottom solely due to gravity. The embodiment also contains an infeed pipe 31 for the production of a mixture 34 of the solid particle 4 with a liquid carrier 32.

Within a method according to the disclosure following this embodiment, the first containers 15/16 are opened in the opening unit 24, whereby the removed solid particles 4 move in a vertical direction from top to bottom and enter the dilution unit 30. There, the liquid carrier 32 is added via the infeed pipe 31, which produces the mixture 34. The mixture 34 then moves into the predosing unit 36, with which predosed units are produced which are then transferred to the filling unit 26 and filled into the second containers 14.

FIG. 5 schematically illustrates a section of a preferred embodiment of the opening unit 24 which contains a perforator 24. Within the opening step, a first container 15/16 is opened with the perforator 24, in that the perforator 36 perforates the closed container in a vertical direction from top to bottom, so that the solid particles 4 emerge from the funnel-shaped opening on the underneath of the container 15/16 in the direction of the arrow. 

1. A method for the aseptic filling of a liquid food product, which contains at least one solid particle, comprising: Disinfecting at least one part of the external surface of at least one first container that comprises the solid particle, and disinfecting at least one second container, Opening the disinfected first container and removing the solid particle, and Filling a disinfected second container with the solid particle and a liquid food (18).
 2. The method according to claim 1, and one of wherein the external surface of the first container is completely disinfected, and the disinfected container is transferred before opening into a clean room; and wherein the first container is only partly disinfected and then a disinfected part of the first container is docked onto an opening unit and opened.
 3. The method according to claim 1, and wherein, between the step of opening in the opening unit and the step of filling: one of producing a mixture of the solid particle with a liquid carrier in a dilution unit, predosing one of the solid particle and the mixture of solid particle with the liquid carrier in a predosing unit, and a combination thereof.
 4. The method according to claim 3, wherein the solid particle removed from the first container or the mixture (34) runs consecutively through the opening unit, the dilution unit and the predosing unit in a vertical direction from top to bottom.
 5. The method according to claim 1, wherein the step of opening comprises the perforation of the first container with a perforator.
 6. The method according to claim 1, further comprising one of testing the leak-tightness of the first container which contains the solid particle, detecting metal in a second container filled with liquid food product with a metal detector, and a combination thereof, wherein the containers are sorted out in the event of one of a leak, the presence of metal, and a combination thereof.
 7. The method according to claim 1, further comprising pasteurizing one of the liquid food, the liquid carrier, and a combination thereof with a pasteurization unit.
 8. The method according to claim 2, further comprising one of introducing one of the first container which contains the solid particle, the empty second container, and a combination thereof into the clean room via at least one first transfer device, removing one of the empty first container the second container filled with the liquid food product, and a combination thereof from the clean room via at least one second transfer device, and a combination thereof.
 9. A device for the aseptic filling of a liquid food product that contains at least one solid particle, comprising at least one disinfection unit to disinfect at least one part of the external surface of at least one first container that contains the solid particle and to disinfect at least one second container, at least one opening unit to open the disinfected first container and to remove the solid particle, and at least one filling unit for filling a disinfected second container with a liquid food and the solid particle.
 10. The device according to claim 9, further comprising one of a clean room in which the opening unit is located, and in which a completely disinfected first container is opened, a docking unit which is located at the opening unit and onto which a disinfected part of the container is docked before opening, and a combination thereof.
 11. The device according to claim 9, further including one of a dilution unit for producing a mixture of the solid particle with a liquid carrier, a predosing unit for predosing one of the solid particle and the mixture of the solid particle with the liquid carrier, and a combination thereof.
 12. The device according to claim 11, wherein the opening unit, the dilution unit and the predosing unit are laid out in a vertical direction from top to bottom.
 13. The device according to claim 9, further comprising one of a testing unit for testing the leak-tightness of the first container which contains the solid particle, a metal detector to detect metal in a second container filled with liquid food product, and a combination thereof.
 14. The device according to claim 9, further comprising at least one pasteurization unit for pasteurizing one of the liquid food, the liquid carrier, and a combination thereof.
 15. The device according to claim 9, further comprising one of at least one first transfer device to introduce one of the first container, which contains the solid particle, an empty second container, and a combination thereof into the clean room, at least one second transfer device to remove one of an empty first container, a second container filled with the liquid food product, and a combination thereof from the clean room, and a combination thereof.
 16. The method according to claim 4, wherein the downward movement is due to gravity.
 17. The method according to claim 5, wherein the perforator perforates the container in a vertical direction from top to bottom.
 18. The method according to claim 7, wherein the pasteurization step is carried out without treating the solid particle.
 19. The device according to claim 12, and wherein the opening unit comprises a perforator.
 20. The device according to claim 19, wherein the perforator is positioned in such a way in relation to the first container that the perforator can perforate the first container in a vertical direction from top to bottom.
 21. The device according to claim 14, and wherein the pasteurization unit is laid out in such a way that the solid particle is not treated. 